INSTALLATION INSTRUCTIONS · DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: +45 9614 9614 · Fax: +45 9614 9615 · [email protected] · Compact Genset Controller, CGC 400 Mounting

DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: +45 9614 9614 · Fax: +45 9614 9615 · [email protected] · www.deif.com



INSTALLATION INSTRUCTIONS

Compact Genset Controller, CGC 400● Mounting● Terminal overview● Wiring● Communication wiring● Unit dimensions and cutouts

Document no.: 4189340785CSW version: 1.00

1. General information1.1. Warnings, legal information and safety..................................................................................................3

1.1.1. Warnings and notes ......................................................................................................................31.1.2. Legal information and disclaimer ..................................................................................................31.1.3. Safety issues ................................................................................................................................31.1.4. Electrostatic discharge awareness ...............................................................................................31.1.5. Factory settings ............................................................................................................................3

1.2. About the installation instructions...........................................................................................................41.2.1. General purpose ...........................................................................................................................41.2.2. Intended users ..............................................................................................................................41.2.3. Contents and overall structure ......................................................................................................4

2. Mounting2.1. CGC 400 mounting.................................................................................................................................5

2.1.1. Mounting of the unit.......................................................................................................................52.1.2. Unit dimensions and panel cutout..................................................................................................52.1.3. Tightening torques.........................................................................................................................6

3. Terminals3.1. Terminal overview and description.........................................................................................................7

3.1.1. Terminal overview..........................................................................................................................73.1.2. Terminal description .....................................................................................................................7

4. Wiring4.1. Wiring diagram.....................................................................................................................................114.2. DC connections....................................................................................................................................12

4.2.1. Communication, multi-input and tacho wiring instructions ..........................................................124.2.2. Binary inputs................................................................................................................................12

4.3. Breaker selection..................................................................................................................................134.3.1. Breaker selection.........................................................................................................................13

4.4. Connection of the 3-phase voltage and current...................................................................................154.4.1. Connection of the 3-phase voltage and current...........................................................................154.4.2. 3-phase AMF wiring ....................................................................................................................16

4.5. Connection of the 1-phase voltage and current...................................................................................174.5.1. 1-phase wiring ............................................................................................................................174.5.2. 1-phase AMF wiring ....................................................................................................................18

4.6. Connection of the split-phase voltage and current...............................................................................194.6.1. Split-phase wiring .......................................................................................................................194.6.2. Split-phase AMF wiring ...............................................................................................................20

5. Communication5.1. Wiring instructions................................................................................................................................215.2. Modbus RTU........................................................................................................................................22

5.2.1. Connection with 2-wire shielded cable (recommended) .............................................................225.2.2. Connection with 3-wire shielded cable........................................................................................23

5.3. CAN bus engine communication..........................................................................................................245.3.1. Connection with 2-wire cable (recommended) ...........................................................................245.3.2. Connection with 3-wire shielded cable .......................................................................................25

CGC 400 installation instructions4189340785 UK

DEIF A/S Page 2 of 25

1. General information1.1 Warnings, legal information and safety

1.1.1 Warnings and notesThroughout this document, a number of warnings and notes with helpful user information will be presented.To ensure that these are noticed, they will be highlighted as follows in order to separate them from the gener-al text.

Warnings

Warnings indicate a potentially dangerous situation, which could result in death, personal in-jury or damaged equipment, if certain guidelines are not followed.

Notes

Notes provide general information, which will be helpful for the reader to bear in mind.

1.1.2 Legal information and disclaimerDEIF takes no responsibility for installation or operation of the generator set. If there is any doubt about howto install or operate the engine/generator controlled by the unit, the company responsible for the installation orthe operation of the set must be contacted.

The unit is not to be opened by unauthorised personnel. If opened anyway, the warranty will belost.

DisclaimerDEIF A/S reserves the right to change any of the contents of this document without prior notice.

1.1.3 Safety issuesInstalling and operating the unit may imply work with dangerous currents and voltages. Therefore, the instal-lation should only be carried out by authorised personnel who understand the risks involved in working withlive electrical equipment.

Be aware of the hazardous live currents and voltages. Do not touch any AC measurement in-puts as this could lead to injury or death.

DEIF do not recommend to use the USB as the primary power supply for the unit.

1.1.4 Electrostatic discharge awarenessSufficient care must be taken to protect the terminal against static discharges during the installation. Once theunit is installed and connected, these precautions are no longer necessary.

1.1.5 Factory settingsThe unit is delivered from factory with certain factory settings. These are based on average values and arenot necessarily the correct settings for matching the engine/generator set in question. Precautions must betaken to check the settings before running the engine/generator set.


General information


1.2 About the installation instructions

1.2.1 General purposeThese Installation Instructions mainly include general product and hardware information, mounting instruc-tions, terminal strip descriptions, I/O lists and wiring descriptions.

The general purpose of this document is to give the user important information to be used in the installation ofthe unit.

Please make sure to read this document before starting to work with the unit and the genset tobe controlled. Failure to do this could result in human injury or damage to the equipment.

1.2.2 Intended usersThese Installation Instructions are mainly intended for the person responsible for the design and installation.In most cases, this would be a panel builder designer. Naturally, other users might also find useful informationin the document.

1.2.3 Contents and overall structureThis document is divided into chapters, and in order to make the structure simple and easy to use, eachchapter will begin from the top of a new page.


General information


2. Mounting2.1 CGC 400 mounting

2.1.1 Mounting of the unitThe unit is designed for mounting by means of six fixing clamps, which are included at delivery.

2.1.2 Unit dimensions and panel cutoutThe unit is designed for mounting in the panel front.

In order to ensure optimum mounting, the panel door must be cut out according to the following measure-ments:

H × W (mm) = 160.0 × 220.0 (+0.4/-0.0)

H × W (inches) = 6.30" × 8.66" (+0.01575/-0.0)

17

4.1

(6.8

5)

234.1 (9.22)

15

8.5

(6.2

4)

218.5 (8.60)

38

.1 (

1.5

0)

45

.6 (

1.8

0)

0.3 Nm


Mounting


2.1.3 Tightening torques

Unit panel door mounting: 0.3 Nm (see diagram in "Unit dimensions and panel cutout")Plug connections (terminals): 0.5 Nm


Mounting


3. Terminals3.1 Terminal overview and description

3.1.1 Terminal overviewCGC 400 unit rear view

6 7 83 4 51 2

+ -

Power

supplyStatus

Multi-functional

inputs

Co

m

Generator voltage

33 34 35 36 37 38

L1 N L2 L3NA NA

10 11 12 13 14 15 16 1817

Binary inputs

20 21 22 24 2523 26 27

Mains voltage

28 29 30 31 32

L1 N L2 L3NA

45 46 47 48

L1 L2 L3

Generator current

39 40 41 42 43 44

MP

U

Co

m

W/L

RPM inputs

GB MB

USB

Emer.

stop

58 59

Relays

RS485

Modbus

55

54

53

B(-)

GND

A(+)

CAN J1939

50

49

CAN H

CAN L

51

GND

s1 s2 s1 s2 s1 s2

56 57

Terminals 28-32, 56-57 and 58-59 are not available in CGC 412.

3.1.2 Terminal description

Description of terms For the relay outputs, the following terms will be used:NO means Normally Open.NC means Normally Closed.Com. means common terminal for the individual relay.


Terminals


Term Technical data Description

1 Power supply + Auxiliary supply

2 Power supply -

3-4* Status output 2 A @ 35 Vdc General status output/configurable

Digital input

10 Digital input Remote start/configurable

11 Digital input Remote stop/configurable

12 Digital input Remote alarm ack./configurable

13 Digital input Shutdown override/configurable

14 Digital input Configurable

15 Digital input Configurable

56** Digital input Configurable

57** Digital input Configurable

Output

20 Emergency stop and common for21 to 23

Common for relay start prepare, starter (crank) and run coil,and input for emergency stop

21 Relay output 21 Start prepare/configurable, function NO

22 Relay output 22 Starter (crank)/configurable, function NO

23 Relay output 23 Run coil/configurable, function NO

24-25 Relay output 24 Horn/configurable function NO

26-27 Relay output 26 Configurable, function NO

Multi-functional inputs

5 Common Common for term. 6 to 8 and 58 to 59

6 RMI6 4 to 20 mA/binary input Fuel level/configurable

7 RMI7 4 to 20 mA/binary input Oil pressure/configurable

8 RMI8 4 to 20 mA/binary input Water temp./configurable

58** RMI58 4 to 20 mA/resistive/binaryinput

● Resistive input or● 4 to 20 mA from active transducer or● Binary with wire break● Pt100● Pt1000

59** RMI59 4 to 20 mA/resistive/binaryinput

● Resistive input or● 4 to 20 mA from active transducer or● Binary with wire break● Pt100● Pt1000

Tacho RPM input

16 RPM input (MPU) Magnetic pickup/tacho generator

17 RPM-GND Common for RPM input. Internally connected to terminal 2

18 RPM input (W/L) Magnetic pickup. PNP, NPN or charge alternator W term.


Terminals


Term Technical data Description

3-phase generator voltage input

33 Gen. voltage L1 GENERATOR VOLTAGE

34 Gen. neutral

35 Not used, must not be connected

36 Gen. voltage L2

37 Not used, must not be connected

38 Gen. voltage L3

3-phase generator current input

39 Gen. current L1, s1 GENERATOR CURRENT

40 Gen. current L1, s2





3-phase mains voltage inputs

28** Mains voltage L1 MAINS VOLTAGE

29** Mains voltage neutral

30** Mains voltage L2

31** Not used, must not be connected

32** Mains voltage L3

Breaker relays

45 Relay R45 Generator circuit breaker/configurable, function NO (normallyopen)46 Relay R45

Optional relay for closing mains breaker

47 Relay R47 Mains circuit breaker/configurable, function NC (normallyclosed)48 Relay R47

Modbus RS 485

49 B(-) Modbus RS-485 RTU. Speed is fixed to 9600 bit/s.

50 GND

51 A (+)

CAN bus port: engine interface

53 CAN-H The CAN bus interface to J1939. The 120 ohm termination re-sistor is wired internally. It is not needed to add an external re-sistor.

54 CAN-GND

55 CAN-L

* The status relay is the uP watchdog output. This relay is normally energised, and the switchis closed after power-up. If the uP fails or the power is lost, the relay will de-energise and theswitch will open. If the unit fails to start up at power-up, then the relay switch will remain open.


Terminals


**Terminals are not available in CGC 412.

The relay output functions are configurable via the PC utility software and can be configured to cover the fol-lowing functions:

● Alarm/limit● Engine run indication● Horn● Idle speed output● Not used● Prepare● Run coil● Starter● Stop coil● Engine heater● Fuel pump

It is possible to choose run coil on one relay and stop coil on another, thus supporting engines with doublesystems.

The multi-functional inputs can be configured to cover the following functions:● RMI sensor input● Pt100 and Pt1000● 4 to 20 mA input● Binary input with wire break (switch function)

Tacho RPM input (MPU) can be configured to cover the following functions:● Magnetic pickup (2-wire)● NPN or PNP pickup (these RPM inputs require external equipment)

Tacho RPM input with capacitor (W/L) can be configured to cover the following functions:● Magnetic pickup (2-wire)● W terminal on charger alternator● NPN or PNP (these RPM inputs require external components)

The generator voltage and current input can be configured to the following:● Voltage 100 to 25000 V primary● Current 5 to 9000 A primary


Terminals


4. Wiring4.1 Wiring diagramThe wiring diagram below shows the default factory settings, but the use of inputs and outputs can be chosenfreely.

+

56

57

-

Remote stop

17

5

Common

Common

- + - +

27

26

25

12

CGC 400

1

2

R24

R23

USB

R22

R21

24

23

22

21

20

4

3

15

14

13

11

10

Shutd. override

Alarm ack.

Remote start

Programming

tool

Battery

Emer. STOP

Status

Start prep.

Starter

RUN coil

Fuse

Alarm horn

AlarmR26

It is important to protect the unit against damage caused by high voltages. Therefore, the fusemust not be more than 2 A slow-blow.


Wiring


4.2 DC connections

4.2.1 Communication, multi-input and tacho wiring instructions


PT100/1000 sensors

GND

A (+)

B (-)

Modbus

49

50

51


RMI sensors


Analogue 4-20 mA

8

7

6


Binary input w.wirebreak

5

8

7

6

5

- +

- +

- +

R

R

R

53

54

55

CGC

GND

CAN L

CAN H

Engine communication

Tacho input

Magnetic pickup/

Tacho generator

16

17

Tacho input

NPN/PNP pickup

18

17

Tacho input

W input from charger

alternator

18

17out

+24V DC B+W

B-

CGC

CGC CGC

CGC CGC CGC

8

7

6

RMI

RMI

RMI

5

CGC

8

7

6

PT 100

PT 100

PT 100

5

CGC

Wiring of RMI 58 and 59 is done the same way as RMI 6-8

4.2.2 Binary inputsBinary inputs 10 to 15 and 56 to 57 have an internal common positive (+), this means that they are triggeredby a connection to negative (-).


Wiring


Dig. input

CGC 400

Term. 5

Com

The binary inputs use fixed signals. Only the mode shift input and the test input (if the timer isused) use pulse signal.

4.3 Breaker selection

4.3.1 Breaker selectionThe controller can handle pulse, continuous and compact breakers. Selection of the breaker type is done inthe application configuration with the PC utility software. Output for breaker handling is chosen in the I/O con-figuration of the PC utility software. In the table below is listed which outputs are needed for breaker handlingdepending on the breaker type.

Breaker type GB on/MB on/TB on GB off/MB off/TB off

Pulse breaker X X

Continuous breaker X

Compact breaker X X

The pictures below are examples of how to set up breakers.


Wiring


Continuous breaker output selection Pulse breaker output selection


Wiring


4.4 Connection of the 3-phase voltage and current

4.4.1 Connection of the 3-phase voltage and currentWiring, AC interface

33

36

34

38

40I1

39

42I2

41

44I3

43

s1

s1

s2

s2

GENERATOR

GENERATOR

VOLTAGE

GENERATOR

CURRENT

UL1

UL2

UL3

N

46

45

14

GB

s1

s2

GB OFF feedback

GB ON

command

Supply

Consumer

L1 L2 L3 N CGC 400


Wiring


4.4.2 3-phase AMF wiring

MAINS

L1 L2 L3 N

28 UL1

29

UL230

UL332

N

33

36

34

38

40I1

39

42I2

41

44I3

43

s1

s1

s2

s2

GENERATOR

MAINS

VOLTAGE

GENERATOR

VOLTAGE

GENERATOR

CURRENT

UL1

UL2

UL3

N

46

45

14

GB

15

48

47

MB

s1

s2

Consumers

CGC 400

MB OFF feedback

GB OFF feedback

GB ON

command

MB ON

command

Supply


Wiring


4.5 Connection of the 1-phase voltage and current

4.5.1 1-phase wiring

33

34

40I1

39

GENERATOR

GENERATOR

VOLTAGE

GENERATOR

CURRENT

UL1

N

46

45

14

GB

s1

s2

GB OFF feedback

GB ON

command

Supply

L1 N CGC 400


Wiring


4.5.2 1-phase AMF wiring

MAINS

L1 N

28 UL1

29 N

33

34

40I1

39

GENERATOR

MAINS

VOLTAGE

GENERATOR

VOLTAGE

GENERATOR

CURRENT

UL1

N

46

45

14

GB

15

48

47

MB

s1

s2

Consumers

CGC 400

MB OFF feedback

GB OFF feedback

GB ON

command

MB ON

command

Supply


Wiring


4.6 Connection of the split-phase voltage and current

4.6.1 Split-phase wiring

33

36

34

40I1

39

42I2

41s1

s2

GENERATOR

GENERATOR

VOLTAGE

GENERATOR

CURRENT

UL1

UL2

N

46

45

14

GB

s1

s2

GB OFF feedback

GB ON

command

Supply

Consumer

L1 L2 N CGC 400


Wiring


4.6.2 Split-phase AMF wiring

MAINS

L1 L2 N

28 UL1

31

UL230

N

33

36

34

40I1

39

42I2

41s1

s2

GENERATOR

MAINS

VOLTAGE

GENERATOR

VOLTAGE

GENERATOR

CURRENT

UL1

UL2

N

46

45

14

GB

15

48

47

MB

s1

s2

Consumers

CGC 400

MB OFF feedback

GB OFF feedback

GB ON

command

MB ON

command

Supply


Wiring


5. Communication5.1 Wiring instructionsCableBelden 3106 A or equivalent. 22 AWG (0.324 mm2) shielded twisted pair, min. 95 % shield coverage.

Cable shieldConnect the cable shield to earth at one end only.

GND terminal connectionIn case of communication problems, the GND terminals of the CGC 400 unit and the external device can belinked together using a third wire.

CAN bus termination resistorThe size of the terminating resistors should be 120 Ω 1 %, 0.5 W resistor.

Never connect the GND terminal to earth directly or through the shield!

If the GND terminal is connected to a PLC or other device, the GND connection of this devicemust be isolated from earth!

Maximum length of the CAN bus line is 400 m.


Communication


5.2 Modbus RTU

5.2.1 Connection with 2-wire shielded cable (recommended)

CGC DA

TA

- (B)

49 50 51

DA

TA

(GN

D)

DA

TA

+ (A

)

CGCDA

TA

- (B)

49 50 51

DA

TA

(GN

D)

DA

TA

+ (A

)

DA

TA

+ (A

)

PLC or other device

DA

TA

(GN

D)

DA

TA

- (B)


Communication


5.2.2 Connection with 3-wire shielded cable

CGCDA

TA

- (B)

49 50 51

DA

TA

(GN

D)

DA

TA

+ (A

)

CGCDA

TA

- (B)

49 50 51

DA

TA

(GN

D)

DA

TA

+ (A

)

DA

TA

+ (A

)

PLC or other device

DA

TA

(GN

D)

DA

TA

- (B)

For wiring details, please refer to “Wiring instructions” in this section.

In case of very long lines on the network, terminating resistors might be needed (typically 120Ω 1 %, 0.5 W).

The calculation should be based on the following data:A line internal pull-up bias resistor: 22 kΩB line internal pull-down bias resistor: 22 kΩReceiver input sensitivity: +/-200 mVReceiver input impedance: 12 kΩ


Communication


5.3 CAN bus engine communication

5.3.1 Connection with 2-wire cable (recommended)

CGC

CA

N-H

53 54 55

Co

m

CA

N-L

CA

N-L

ECM

engine control module

Co

m

CA

N-H

R

R


Communication


5.3.2 Connection with 3-wire shielded cable

CGC

CA

N-H

53 54 55

Co

m

CA

N-L

CA

N-L

ECM

engine control module

Co

m

CA

N-H

R

R


Communication


Documents

INSTALLATION INSTRUCTIONS · DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: +45 9614 9614 · Fax: +45 9614 9615 · [email protected] · Compact Genset Controller, CGC 400 Mounting